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V-LINE® Direct CastingInjection Molding Machine for Aluminum Alloy

ALM450

World's First*

Features of "ALM450"

V-LINE®Direct CastingAdopted the V-LINE® Direct Casting structure equipped with a melting cylinder which melts the aluminum, and an injection cylinder that injects the material into the mold.The separated melting and injection processes enable accurate and efficient molding.

Sodick's Hybrid Direct Pressure Mold Clamping(SHDC)Smooth mold opening/closing is possible while maintaining accurate parallelism of the platens and high straightness of operation, which realizes excellent molding quality and reduces the maintenance frequency by preventing damage to the mold.

2 3

Superiority of "ALM450"

Released injection molding machine for aluminum alloy without a melting furnace and holding furnace*1

Aluminum Molding RevolutionThe "ALM450" enables excellent injection molding of aluminum alloy without a melting furnace and holding furnace, by Sodick's unique technology based on space-saving and safe design.The development of this revolutionary molding accelerates the replacement of materials from steel to aluminum, thinner, more complicated and refinement of existing aluminum molded products, which brings an energy saving effect to automobile related and other related fields by weight reduction.

ALM450*1: Based on Sodick's research

V-LINE®Direct Casting

SHDCSodick Hybrid Direct Clamp

This machine is designed so that peripheral equipment, including a melting furnace that melts the aluminum, holding furnace that maintains the melted aluminum state, ladle that supplies the melted aluminum to the sleeve of the die casting machine, and a robot are not required which reduces the space to install this equipment, and improves safety because maintenance is not necessary.

No melting furnace and holding furnace

Holds the molten bath close to the product of the mold which improves the appearance quality of thin products, because the bath flows easily without cooling down. The reduced entrainment of air by low speed injection allows the pressure to be transmitted directly by the holding pressure effect, which reduces the internal defect phenomena of thick products. It also allows injection at a high vacuum realm, which reduces the cavities in the casting. *2

Capable of various types of molding

The environment-friendly structure demonstrates efficient energy savings, because the amount of aluminum only required per molding cycle is melted. In addition to space-saving, improvements in safety and reduction of maintenance, the molding machine can be stopped and restarted easily, because it is not necessary to remove the molten bath that remains in the cylinder.

Excellent usability

*2: Separate vacuum equipment is required

*3: Hot chamber method: The casting method of light metals except for aluminum. This method is not yet ready for aluminum. A pressure chamber is provided in the molten bath without a melting furnace and holding furnace.

Features of V-LINE® Direct Casting: Comparison with conventional method (Die casting method)

Name

Yield and quality

Space

Melting temperature

Holding pressure

Although the melting temperature of aluminum for die casting is 600 ºC, the melting and holding is controlled from 720 ºC to 750 ºC in the melting furnace and holding furnace to prevent solidification of the aluminum to be supplied.

After the molten bath is supplied to the sleeve, a plunger is pushed in to supply the molten bath into the mold. Low stability of the quality and yield, because the start of solidification of the melted aluminum and entrainment of air cannot be avoided.

In addition to the die casting machine, peripheral equipment, such as a melting furnace, holding furnace, ladle and robot are required.

Conventional method: Cold chamber method

Since the melted aluminum is always held in the flow path without contacting ambient air, only the melting temperature is required which contributes to energy saving.

The aluminum is melted in the melting cylinder, measured by the injection cylinder, and after back flow prevention is applied it is injected. The quality and yield can be improved because it holds the melted state of the aluminum without entrainment of air.

The installation space of the ALM450 (including heater power supply) is all that is required.

Sodick: V-LINE® Direct Casting

1. Mold clamping (Supply molten bath)

2. During injection (During casting)

3. Injection completed (Casting completed)

Plunger

Melting aluminum

Sleeve

A high pressure force is required because the almost hardened biscuit is pressed at a high pressure, which generates a pressure loss even on the inside.

Directly applying pressure to the molten bath, transfers the material to the fine portions of the product.

Backflow prevention pin

Injection cylinder

Melting cylinder

Technological features

Light metal die casting, particularly the main casting method of aluminum products *3

●Equipped with a melting furnace and holding furnace●No pressure chamber in the molten bath

Sodick's uniquely developed injection molding of aluminum molded products●No melting furnace and holding furnace●Molten bath flows through the cylinder

World's First*

Features of "ALM450"

V-LINE®Direct CastingAdopted the V-LINE® Direct Casting structure equipped with a melting cylinder which melts the aluminum, and an injection cylinder that injects the material into the mold.The separated melting and injection processes enable accurate and efficient molding.

Sodick's Hybrid Direct Pressure Mold Clamping(SHDC)Smooth mold opening/closing is possible while maintaining accurate parallelism of the platens and high straightness of operation, which realizes excellent molding quality and reduces the maintenance frequency by preventing damage to the mold.

2 3

Superiority of "ALM450"

Released injection molding machine for aluminum alloy without a melting furnace and holding furnace*1

Aluminum Molding RevolutionThe "ALM450" enables excellent injection molding of aluminum alloy without a melting furnace and holding furnace, by Sodick's unique technology based on space-saving and safe design.The development of this revolutionary molding accelerates the replacement of materials from steel to aluminum, thinner, more complicated and refinement of existing aluminum molded products, which brings an energy saving effect to automobile related and other related fields by weight reduction.

ALM450*1: Based on Sodick's research

V-LINE®Direct Casting

SHDCSodick Hybrid Direct Clamp

This machine is designed so that peripheral equipment, including a melting furnace that melts the aluminum, holding furnace that maintains the melted aluminum state, ladle that supplies the melted aluminum to the sleeve of the die casting machine, and a robot are not required which reduces the space to install this equipment, and improves safety because maintenance is not necessary.

No melting furnace and holding furnace

Holds the molten bath close to the product of the mold which improves the appearance quality of thin products, because the bath flows easily without cooling down. The reduced entrainment of air by low speed injection allows the pressure to be transmitted directly by the holding pressure effect, which reduces the internal defect phenomena of thick products. It also allows injection at a high vacuum realm, which reduces the cavities in the casting. *2

Capable of various types of molding

The environment-friendly structure demonstrates efficient energy savings, because the amount of aluminum only required per molding cycle is melted. In addition to space-saving, improvements in safety and reduction of maintenance, the molding machine can be stopped and restarted easily, because it is not necessary to remove the molten bath that remains in the cylinder.

Excellent usability

*2: Separate vacuum equipment is required

*3: Hot chamber method: The casting method of light metals except for aluminum. This method is not yet ready for aluminum. A pressure chamber is provided in the molten bath without a melting furnace and holding furnace.

Features of V-LINE® Direct Casting: Comparison with conventional method (Die casting method)

Name

Yield and quality

Space

Melting temperature

Holding pressure

Although the melting temperature of aluminum for die casting is 600 ºC, the melting and holding is controlled from 720 ºC to 750 ºC in the melting furnace and holding furnace to prevent solidification of the aluminum to be supplied.

After the molten bath is supplied to the sleeve, a plunger is pushed in to supply the molten bath into the mold. Low stability of the quality and yield, because the start of solidification of the melted aluminum and entrainment of air cannot be avoided.

In addition to the die casting machine, peripheral equipment, such as a melting furnace, holding furnace, ladle and robot are required.

Conventional method: Cold chamber method

Since the melted aluminum is always held in the flow path without contacting ambient air, only the melting temperature is required which contributes to energy saving.

The aluminum is melted in the melting cylinder, measured by the injection cylinder, and after back flow prevention is applied it is injected. The quality and yield can be improved because it holds the melted state of the aluminum without entrainment of air.

The installation space of the ALM450 (including heater power supply) is all that is required.

Sodick: V-LINE® Direct Casting

1. Mold clamping (Supply molten bath)

2. During injection (During casting)

3. Injection completed (Casting completed)

Plunger

Melting aluminum

Sleeve

A high pressure force is required because the almost hardened biscuit is pressed at a high pressure, which generates a pressure loss even on the inside.

Directly applying pressure to the molten bath, transfers the material to the fine portions of the product.

Backflow prevention pin

Injection cylinder

Melting cylinder

Technological features

Light metal die casting, particularly the main casting method of aluminum products *3

●Equipped with a melting furnace and holding furnace●No pressure chamber in the molten bath

Sodick's uniquely developed injection molding of aluminum molded products●No melting furnace and holding furnace●Molten bath flows through the cylinder

V-LINE® Direct Casting Injection Molding Machine for Aluminum Alloy ALM450

5

Sodick's unique V-LINE® Direct Casting realized

through the application of independently developed

materials that suppress the melting loss by melting

aluminum to the flow path of the melting cylinder

that melts the aluminum and the injection cylinder

that injects the melted aluminum, provides

innovated injection molding of aluminum alloy.

Realized Injection Molding of Aluminum Alloy

■Molding Process of V-LINE® Direct Casting

InjectionBackflow preventionMeasurementMelt Hold

pressureSupply

By independently controlling the entire process from injection to melting, the V-LINE® Direct Casting

realizes three stability factors;　 melted state of the aluminum,　 measurement of the aluminum volume, and　　actual filling volume.

12 3

■Molding Material and Material Supply UnitAluminum with a diameter of φ90 mm or φ120 mm and length of 200 mm is used as the molding material.Several aluminum billets are supplied to the stocker, and are automatically supplied to the melting cylinder one at a time. The material can be controlled more safely.

■Structure of V-LINE® Direct CastingThe aluminum billets supplied from the supply unit are inserted into the melting cylinder, and are melted by a heater.This system is designed so that the aluminum required for one shot is supplied to the injection cylinder.

■Direct NozzleThe direct nozzle which directly contacts the mold realizes a stable molding quality.

4

Molding material: Aluminum billets

SupplyM

elt

●Supply 1 A billet is inserted from the supply unit to the supply port.

●MeltingMelted in the melting cylinder.

●Backflow preventionThe backflow prevention pin moves forward to close the flow path.

V-LINE® Direct Casting

Supply unit Direct nozzle

Measurem

entBackflow

preventionInjection

Hold pressureStable melted state1 Stable actual filling volume3

Stable measurement of aluminum volume2

All the aluminum is filled into the mold

No backflow during injection

Injection after the active closure of the flow path

●MeasurementThe unmelted and semi-melted billet in front of the pusher supplies melted aluminum to the injection cylinder.

■Structure of V-LINE® Direct CastingAluminum billet

Stocker Material supply unit

Backflow prevention pin

Injection cylinderDirect nozzle Injection plunger Hydraulic injection cylinder

Material pusher

Heating heater

Melting cylinder

●Supply 2 A pusher moves forward to supply the billet to the melting cylinder.This operation is repeated for the volume of one shot.

Melted aluminum

Semi-melted aluminum

Unmelted aluminum

■Effectiveness of V-LINE® Direct Casting

There are almost no factors that would accelerate the solidification during injection, because the distance between the molten bath in the nozzle and the mold is very close.

Low speedEffectiveness

1 The pressure spreads into the f ine portions at a low pressure, because the holding pressure directly applies pressure on t he bath , wh ich i s effective in reducing internal defects.

Low pressureEffectiveness

2 The temperature is controlled to the nozzle at a relatively low temperature, which suppresses the occurrence of hydrogen.

Low temperatureEffectiveness

3

V-LINE® Direct Casting Injection Molding Machine for Aluminum Alloy ALM450

5

Sodick's unique V-LINE® Direct Casting realized

through the application of independently developed

materials that suppress the melting loss by melting

aluminum to the flow path of the melting cylinder

that melts the aluminum and the injection cylinder

that injects the melted aluminum, provides

innovated injection molding of aluminum alloy.

Realized Injection Molding of Aluminum Alloy

■Molding Process of V-LINE® Direct Casting

InjectionBackflow preventionMeasurementMelt Hold

pressureSupply

By independently controlling the entire process from injection to melting, the V-LINE® Direct Casting

realizes three stability factors;　 melted state of the aluminum,　 measurement of the aluminum volume, and　　actual filling volume.

12 3

■Molding Material and Material Supply UnitAluminum with a diameter of φ90 mm or φ120 mm and length of 200 mm is used as the molding material.Several aluminum billets are supplied to the stocker, and are automatically supplied to the melting cylinder one at a time. The material can be controlled more safely.

■Structure of V-LINE® Direct CastingThe aluminum billets supplied from the supply unit are inserted into the melting cylinder, and are melted by a heater.This system is designed so that the aluminum required for one shot is supplied to the injection cylinder.

■Direct NozzleThe direct nozzle which directly contacts the mold realizes a stable molding quality.

4

Molding material: Aluminum billets

SupplyM

elt

●Supply 1 A billet is inserted from the supply unit to the supply port.

●MeltingMelted in the melting cylinder.

●Backflow preventionThe backflow prevention pin moves forward to close the flow path.

V-LINE® Direct Casting

Supply unit Direct nozzle

Measurem

entBackflow

preventionInjection

Hold pressureStable melted state1 Stable actual filling volume3

Stable measurement of aluminum volume2

All the aluminum is filled into the mold

No backflow during injection

Injection after the active closure of the flow path

●MeasurementThe unmelted and semi-melted billet in front of the pusher supplies melted aluminum to the injection cylinder.

■Structure of V-LINE® Direct CastingAluminum billet

Stocker Material supply unit

Backflow prevention pin

Injection cylinderDirect nozzle Injection plunger Hydraulic injection cylinder

Material pusher

Heating heater

Melting cylinder

●Supply 2 A pusher moves forward to supply the billet to the melting cylinder.This operation is repeated for the volume of one shot.

Melted aluminum

Semi-melted aluminum

Unmelted aluminum

■Effectiveness of V-LINE® Direct Casting

There are almost no factors that would accelerate the solidification during injection, because the distance between the molten bath in the nozzle and the mold is very close.

Low speedEffectiveness

1 The pressure spreads into the f ine portions at a low pressure, because the holding pressure directly applies pressure on t he bath , wh ich i s effective in reducing internal defects.

Low pressureEffectiveness

2 The temperature is controlled to the nozzle at a relatively low temperature, which suppresses the occurrence of hydrogen.

Low temperatureEffectiveness

3

6 7

Clamping UnitMax. clamping force kN 4,410

Tie bar distance mm 820 × 820

Open daylight (Min. mold thickness + Max. stroke) mm 1,240

Min./Max. mold thickness mm 340 / 900

Mold open/close force Rated/Instantaneous kN 24.7/49.4

Ejector projection force kN 252

Ejector stroke mm 100

Injection unit

Machine dimensions / Weight

Al material diameter mm 90 120

Plunger diameter mm 90 120

Max. injection pressure MPa 50 40

Theoretical injection volume cm3 826 1810

Injection rate cm3/s 31,808 33,929

Max. injection speed mm/s 5,000 3,000

Machine dimensions (L x W x H) mm 9,750 × 1,965 × 2,386

Machine weight kg 21,000 22,000

Evaluation of Molded ProductAs a result of a micro observation of a fractured surface, there were almost no cavities in the microstructure with excellent flowability, and a stable molding quality by the effectiveness of the holding pressure could be confirmed.

Vent side

Gate side

1

2

3

4

5

6

■Fractured surface structure observation ■Fractured surface microstructure observation

Flow of bath

4

5

6Vent side

Gate side

1

2

3

The "ALM450" is equipped with Sodick's unique hybrid direct pressure mold clamping (SHDC).The perfect repeatability of the trajectory required for opening and closing of the mold, and the high level of uniformity and reproducibility required for the mold clamping force, demonstrates an excellent sense of stability of the V-LINE® Direct Casting.

Reproduces accurate and uniform mold clamping forceSodick's Hybrid Direct Pressure Mold Clamping

S od i ck H ybr id D i r e c t C lampSHDC

■SHDC mechanism which supports V-LINE® Direct Casting

Molding Example

A L M 4 5 0

Tablet PC Case

■ConditionsMaterial : Al-Si (4,000 series)Product size : 280×200×10mmThinnest portion : 1.2 mm (Almost entire surface)Nozzle cross-section : 2.5 cm2 = Gate cross-section areaInjection speed : 1.2 m/sec (No low speed area)Holding pressure : 40MPa-0.1secMold temperature : 200 ºC, water cooling for sprue and vent portionsMold lubricant : OilVacuum : None

100

200

T=1.2

100～

280

■Structure of SHDC

Electric servo motor mechanism which accurately controls the position during the mold opening/closing

Hydraulic cylinder mechanism which reproduces a uniform mold clamping force

during the mold clamping

V-LINE® Direct Casting Injection Molding Machine for Aluminum Alloy ALM450

Sp

ec

if

ic

at

io

ns

Movable platen Fixed platenMold clamping cylinder

Ball screw

Tie bar

Mold clamping lock

Mold clamping ram

Mold open/close AC motor

Direct pressure methodGenerates uniform clamping pressure in the center

Maintains long spanEnsures platen position Platen not held by tie bars

Eliminates effect of tie bar strain

High rigidity platen structure

LM guide platen supportEnsures the repeatability of the trajectory

Ensures the linearity of the ball screw drive operation in the center

The repeatability of the trajectory is high with the support of the LM guide and mold c lamping ram, which makes i t easy to maintain the position of the movable platen.

Operation accuracy1 The mold clamping force by hydraul ic

pressure is not affected by disturbances, such as the temperature.

Effect from disturbances2 An unbalanced load does not occur with the

ball screw drive in the center.

Load distribution3

6 7

Clamping UnitMax. clamping force kN 4,410

Tie bar distance mm 820 × 820

Open daylight (Min. mold thickness + Max. stroke) mm 1,240

Min./Max. mold thickness mm 340 / 900

Mold open/close force Rated/Instantaneous kN 24.7/49.4

Ejector projection force kN 252

Ejector stroke mm 100

Injection unit

Machine dimensions / Weight

Al material diameter mm 90 120

Plunger diameter mm 90 120

Max. injection pressure MPa 50 40

Theoretical injection volume cm3 826 1810

Injection rate cm3/s 31,808 33,929

Max. injection speed mm/s 5,000 3,000

Machine dimensions (L x W x H) mm 9,750 × 1,965 × 2,386

Machine weight kg 21,000 22,000

Evaluation of Molded ProductAs a result of a micro observation of a fractured surface, there were almost no cavities in the microstructure with excellent flowability, and a stable molding quality by the effectiveness of the holding pressure could be confirmed.

Vent side

Gate side

1

2

3

4

5

6

■Fractured surface structure observation ■Fractured surface microstructure observation

Flow of bath

4

5

6Vent side

Gate side

1

2

3

The "ALM450" is equipped with Sodick's unique hybrid direct pressure mold clamping (SHDC).The perfect repeatability of the trajectory required for opening and closing of the mold, and the high level of uniformity and reproducibility required for the mold clamping force, demonstrates an excellent sense of stability of the V-LINE® Direct Casting.

Reproduces accurate and uniform mold clamping forceSodick's Hybrid Direct Pressure Mold Clamping

S od i ck H ybr id D i r e c t C lampSHDC

■SHDC mechanism which supports V-LINE® Direct Casting

Molding Example

A L M 4 5 0

Tablet PC Case

■ConditionsMaterial : Al-Si (4,000 series)Product size : 280×200×10mmThinnest portion : 1.2 mm (Almost entire surface)Nozzle cross-section : 2.5 cm2 = Gate cross-section areaInjection speed : 1.2 m/sec (No low speed area)Holding pressure : 40MPa-0.1secMold temperature : 200 ºC, water cooling for sprue and vent portionsMold lubricant : OilVacuum : None

100

200

T=1.2

100～

280

■Structure of SHDC

Electric servo motor mechanism which accurately controls the position during the mold opening/closing

Hydraulic cylinder mechanism which reproduces a uniform mold clamping force

during the mold clamping

V-LINE® Direct Casting Injection Molding Machine for Aluminum Alloy ALM450S

pe

ci

fi

ca

ti

on

s

Movable platen Fixed platenMold clamping cylinder

Ball screw

Tie bar

Mold clamping lock

Mold clamping ram

Mold open/close AC motor

Direct pressure methodGenerates uniform clamping pressure in the center

Maintains long spanEnsures platen position Platen not held by tie bars

Eliminates effect of tie bar strain

High rigidity platen structure

LM guide platen supportEnsures the repeatability of the trajectory

Ensures the linearity of the ball screw drive operation in the center

The repeatability of the trajectory is high with the support of the LM guide and mold c lamping ram, which makes i t easy to maintain the position of the movable platen.

Operation accuracy1 The mold clamping force by hydraul ic

pressure is not affected by disturbances, such as the temperature.

Effect from disturbances2 An unbalanced load does not occur with the

ball screw drive in the center.

Load distribution3

■Machine Dimensions & Installation Drawing

■Mold Installation Dimensions Drawing

T slot dimensions

T slot T slot

V-LINE® Direct CastingInjection Molding Machine for Aluminum Alloy

Unit: mm

ALM450

Printed in Japan

3-12-1, Nakamachidai, Tsuzuki-ku, Yokohama, Kanagawa224-8522 JapanTEL: 81-45-942-3111 FAX: 81-45-943-7880

●�The export of Sodick's products and its related technologies (including software applications) is regulated under Japan's Foreign Exchange and Foreign Trade Control Law. In addition, because some of these products may be subject to re-export controls under the Export Administration Regulations (EAR) of the United States; please contact Sodick before offering or exporting these products overseas.

●This catalogue contains a photographic image that has been generated from 3DCG.●Options may be included in the photos of this catalog.●��Due to ongoing research, specifications are subject to change without prior notice.●The contents of this catalog is current as of August, 2017.

http://www.sodick.jp

R2007600.2017.08<00>